8/5/2021

1

1/21

Panasonic Life Solutions India Pvt. Ltd.Haridwar, Uttarakhand

Presenter –Kapil Kumar (Sr. Engineer) & Kamal Negi (Dy. Manager)

CII National Award for Environmental Best Practices – 2021

Panasonic

Year:1918Year:1963

Panasonic

Year:2007 Now 2019

MCBSwitch, Sockets Switch, Sockets & Accessories

Switch, Sockets & Accessories

2/21Selected Theme By CII

Best Environmental Initiatives

1. Urea Formaldehyde Waste Reduction Through 3R Technique From 24.27% to

23.23% per Month

2. Reduction of Single Use Plastic Waste Through Lifecycle Assessment

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3/21

1-IQC-Raw Material

Urea Formaldehyde Raw Material

Moulding Powder

Process Flow (PFD)-

Molding Process2-Compression Molding Process

Project title - Urea Formaldehyde Waste Reduction Through 3R Technique From 24.27% to 23.23% per Month

Compression molding Process is a method of molding in which the preheated molding material placed in an open,

heated mold cavity. The mold is closed with a top force or plug member and pressure is applied to force the material into contactwith all mold areas, while heat and pressure are maintained until the molding material has cured. In this process we have usedThermoset Urea Formaldehyde Plastic Material.

Flash Scrap (Design Scrap)Molding Scrap (Process Rejection)

Urea Formaldehyde Wastage

3-Product

Urea Molding Scrap

Waste converted into Energy by co processing at Brick Kiln

Safe Disposal

Project Title - Theme No.: 1

4/21Trigger of The Project

Urea FormaldehydeWastage

Metal Scrap Wastage

Oil Consumption in Forming Machine

This Material is Not Recyclable So We Select

This Project

The project is conceived on Middle

management / Operating level

it is a new concept

Schedule of Project

Start This Project

End this Project

Plan Jun-20 Mar-21

Actual Implement

Jun-20 Feb-21

Uniqueness of this Project

1-Innovative Ideas

2-Reduction of Waste generation

3-Horizontal Deployment in Other Plant

4-Machine Improvement in Effective Manner

5-Protection for Environment

Jun-20 to July-20 Project Selection &

Identify Current Status Of

Wastage

Aug 20 to Dec-20Identify Problem Validation

and Countermeasure

Implementation

Feb-21Standardization

Jan -21Efficetivness of

Countermeasure

Project Road Map for Waste Reduction

Meeting With CFT

Company Management

Loss

Panasonic

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8/5/2021

3

5/21Countermeasure & Implementation Against -Urea Formaldehyde Wastage

Issue Cause Implement Countermeasure

Before After Status

Wastage due to Spot Defect

Metal/Magnet Parts In Urea Raw Material Supplier End

Prevention- Implement Magnet At R/M Feeding Box Permanent Countermeasure :

C/M-1 Supplier Change Beads Hardness 6.8 MOH Scale to 9 MOH ScaleC/M-2 Supplier Change Grinder Blade Hardness From 225 to 352

Done

Wastage Due to Short Molding Defect

Raw Material Not Proper Flow From Spacer Due to Less Hole Dia. of Spacer

Increase Spacer Hole Dia. From 15 mm to 20 mm Done

Wastage Due to Excess Flash

Raw Material Density Variation

Standardize the Density of Both Supplier : Density Observed Supplier A 0.76 to 0.82 gm/ml Supplier B 0.81 TO 0.89 gm/ml

As per IS 2221:1962Standardize Density 0.80±0.03

gm/ml

Done

Before-Dia-15 mm

Beads Beads

Grinder Blade Grinder Blade R/M Box Without Magnet R/M Box With Magnet

0.76 to 0.89 gm/ml

After- Dia-20 mm

6/21

S. No. Technical ChallengesAdministrative

ChallengesMaintenance Challenges

Mitigation Measures Results

1

1- How Many Gauss Magnet used to Catch Metal Parts

From R/M2- How We Standardize the

Harness of Beads and Grinder Blade at Supplier end

1- What is the Cost of Magnet and how much Budget required

to Implement in all M/C 2- High cost of Beads and

Grinder Blade

1- Frequency of Magnet Preventive

Maintenance /Replacement

2- Frequency of Grinder Blade and Beads Preventive

Maintenance

Trial on different Gauss magnet Bead, Grinder Blade

& finalize based on Effectives, Cost, Quality and Durability. Maintenance Frequency also

Standardized

Raw Material Quality Improve and Rejection

Reduce

21- How We Standardize

Increase Hole Dia. 15 to 20 mm

1- Modification Cost much higher (Approx. 2.5 Lac by

outside Vendor)

1- Frequency of Spacer Preventive

Maintenance

1-Spacer Hole dia. finalize based on Low Rejection and

set the Maintenance Frequency after trial and verification of shelf Life of

Spacer Wear Out2-Modification done by

Inhouse Maintenance Team

Spacer Hole Dia. Standardizeand Reduce

Short Molding Wastage

3

1- How we calculate Density of R/M as per Standard and

how we Standardize the Density at Supplier End

1- Requirement of Instrument for Density Measurement

2- Improvement at Supplier End in Current Covid-19 Condition

1- Frequency of Density Instrument

Preventive Maintenance /Calibration

1- Standardize R/M Density 0.80±0.03 gm/ml as per IS 2221:1962 & Online Meeting

with Supplier to Maintain Density as per Standard

Raw Material Quality

improved at Supplier end

and Flash Wastage Reduce

Challenges Faced & Brief of Countering

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255814

197003

0

50000

100000

150000

200000

250000

300000

Before FY 19-20 After 20-21

En

rgy (

KW

H)

Energy Saving = 58811 KWH Per Million Pcs

Energy Consumption Reduction

3396

2268

0

500

1000

1500

2000

2500

3000

3500

4000

Before FY 19-20 After 20-21Wa

ter

Co

nsu

mp

tio

n (

Ltr)

Water Consumption Reduction

87.20%

87.60%

87

87.1

87.2

87.3

87.4

87.5

87.6

87.7

Before FY 19-20 After 20-21

M/C

Eff

icie

ncy

(%

M/C Efficiency Increase

209,767

161,543

0

50000

100000

150000

200000

250000

Before FY 19-20 After 20-21

CO

2 E

mis

sio

n(K

g)

Green House Gas Emission

24.27%

23.23%

23

23

23

23

23

24

24

24

24

24

Before FY 19-20 After 20-21

Ure

a W

ast

ag

e (

Kg

)

Urea Formaldehyde Waste Reduction

Waste Reduction = 2711 Kg/ year

CO2 Emission Reduction =48.22 Ton/Year Water Consumption Saving =1.13 KL /year M/C Efficiency Increased 0.40% Per Month

Tangible Benefits

Earth Protection

8/21Intangible Benefits

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9/21Replication Potential of Project within Sector

All Past Data, Trial And Countermeasure History Share to Daman Team for Horizontal Deployment

Meeting With Daman Moulding Team21.12.2020

Haridwar

Moulding

Daman

Moulding

1-Reduce Spot Rejection From 1.18 to 0.84%2-Reduce Short Molding Rejection From 0.86 to

0.66%

1.18

0.84

0.0

0.5

1.0

1.5

Before After Take C/M

Spot Rejection

Re

ject

ion

%

0.86

0.66

0.0

0.2

0.4

0.6

0.8

1.0

Before After Take C/M

Short Moulding Rejection

Re

ject

ion

%

Effectiveness After Horizontal Deployment in Daman Plant

Knowledge Sharing With Cross

Functional Team & Others

Plant Name Defect Countermeasure Where When Before After

Panasonic Life

Solutions India Pvt Ltd

1- Black

Spot

Magnet Implement on

R/M Feeding Box

Daman Dec-20

Panasonic Life

Solutions India Pvt Ltd

2- Short

Moulding

Increase Hole Dia. From

15 mm to 20 mm

Daman Dec-20

1 12 2

10/21

1- Polybag use to avoid Scratches on Aesthetic Parts

Process Flow (PFD)-

Project title - Reduction of Single Use Plastic Waste Through Lifecycle Assessment

Polypropylene (PP) Bags used during the internal transferring of Raw material and Semi Finished Goods from one production

section to another production section. During this internal transferring the role of Poly Bag was in two different ways (i) storage

of raw material/semi finish good small in size (ii) to cover the material (GINA Plates) to keep them free from scratches & damage.

Project Title - Theme No.: 2

Plates (Base) J Box Penta Top

Switch & SocketPlate (Cover) Dimmer 2- Material transfer to Assembly process

3- Empty Polybag collect in Bin

Empty Polybag collected in Scrap yard for disposal through

vendor/ recycler

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11/21Trigger of The Project

Single Use of Plastic Waste

Reduce Mold release spray consumption in Molding M/c

Oil Consumption in Forming M/c

Legal Compliance (Govt. Notification to Ban use of

Single Use Plastic)

The project is conceived on Top management level

Schedule of Project

Start This Project

End this Project

Planning & Implementation

Dec-18 May-19

Uniqueness of this Project

1-Innovative Ideas

2-Reduction of Waste generation

3-Horizontal Deployment in Other Plant

4-Protection for Environment

5-Fulfill Legal Requirement

Project Road Map for Waste Reduction Meeting With CFT

Company Management

Loss

Panasonic

MD Speech

As a part of Panasonic GroupTo move our company to next level, We need to resolve critical Internal

& External Issues

Cause of Environmental

pollution

500 Billion to a Trillion Plastic bags consumed each year

High Costs for clean-upOnly 1% recycledGovernment notification to

ban Single use Plastic

Take upto 2,000 Yrs to Decompose

Oct-18 to Nov-18 Project Selection & Identify Current Status of Polybag

consumption

Dec 18 to Mar-19Identify Problem Validation and

Countermeasure Implementation

May-19Standardization

Apr -19Efficetivness of

Countermeasure

12/21Countermeasure & Implementation Against –Single Use Plastic Wastage

Issue Cause Implement Countermeasure

Before After Status

Use of large size polybag for small parts packing

Increase the plastic waste quantity after use

Small and Big size Corrufabricated box use for packing of switch, socket, dimmer and other semi finish goods (non-woven bag and box are multiple time usage due to its long life)

Done

Use of small size polybag for cover GINA plates

Increase the plastic waste quantity after use

Non-Woven bag & Cover Bin use to replace Polybag to keep free from scratches and damage

Done

Switch and other small parts pack in polybag for transfer

Cover Plates pack in polybag

GINA Plates packing in Non Woven bags

Parts packing in Corrufabricated Box

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S. No. Technical ChallengesAdministrative

ChallengesMaintenance Challenges

Mitigation Measures Results

1

Plastic Waste Reduction:Many type of products are

manufactured hence different sizes of box or tray required

to keep products

Check alternative of Polybag packing to reduce plastic waste

as per Govt. notification

Different type of Box search for product and

trial done. Check Material feasibility on

various aspects.

Brainstorming with team and finalize non-woven bags to

keep plates and box for other small products

Alternative of Polybag

identified

2

Use of Alternative material with long life

cycle:Non availability of cotton

bags and Soft material box in market as per our

requirement

What is the Cost of alternative packing and how much Budget

required to Implementation

Material replacement in alternative packing

Visit of suppliers and develop sample as per our

requirement and standard

Trial of packing completed, and sample finalized

3

Scratch / Damage free product:

Alternative material for keeping products required

scratch or damage free

Follow Work instructions.Awareness training to all

employees regarding use of Non-woven bag and

Corrufabricated box in place of Polybag.

Safe transfer of products in other

departments

Vendor developed for supply of Non-woven bags and Corrufabricated box and replaced the packing for

transfer in other departments

Polybag replaced

Challenges Faced & Brief of Countering

14/21Tangible Benefits

Polybag Consumption Reduced = 134144 Kg

Polybag Cost Reduced = 155.7 Lacs

Total Polybags Consumption Cost =

161.1 Lacs/ Year

Alternate Packing Development Cost =

56.9 Lacs

Net Saving =161 – 5.5 – 56.9

=98.7 Lacs/Year

161.1

5.50.0

50.0

100.0

150.0

200.0

Before Year 2018 After Year 2019

Co

st (

Lac)

Polybag Cost Reduction

139341

5197

0

20000

40000

60000

80000

100000

120000

140000

160000

Before Year 2018 After Year 2019

Qu

an

tity

(K

g)

Polybag Consumption Reduction

96.27 % Consumption

reduced from Injection

Molding

161.1

62.4

0

50

100

150

200

Year 2018 Year 2019

Am

ou

nt

(La

c)

Total Cost Saving (Polybag Vs.

Alternative packing)

Total Cost Saving= 98.7 Lacs

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15/21Intangible Benefits

XReducing the Cause

of Soil Pollution

XReducing the Cause of

Air Pollution

Improved

Team Work

Improved

Project Management

Improved

Problem Solving

Improved

Self Confidence Level

Improved

Moral Values

16/21Replication Potential of Project within Sector

Meeting With Daman Production Team15.12.2020

Haridwar

Production

Section

Daman

Production

Section

100 %

Replication

Potential of

Project

Achievements & Knowledge Sharing PlatformsFuture After Spreading Benefits

Possible Implementation of Evidence

Virtual National Level Meet

Rewards & Recognition @ Global Level

Meet

Replication Factors

Material Feasibility

• Corrugated Box

• Paper Sheet

• High-Quality Bubble Sheet

Product Quality

Process Flow

Inter Sections Working

Material Procurement Cost

Single Use Plastic Reduction

Environment Load

• Transferring of GINA Plates

Without Scratch

• Product Quality Improvement

• Process Improvements

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9

17/21Achieving National Benchmarks/Standards

PANASONIC GLOBAL BENCHMARK

Reduce greenhouse gas emission

to substantially zero by 2050

Top Management From Japan, had lagged behind

in Environmental issues, changed the direction

towards Sustainable

� Zero CO2 Emissions Factories

� Increase Renewable Energy

Resources

� Reduce Water Consumption

� Water Positive Units

� Increase Rainwater Utilization

� Zero Landfilling Waste

� Procurement of Sustainable

Materials

� Chemicals Management

System

PLSIND UNITS BENCHMARK

Wiring Devices Division Environment Standards

� PVC Scrap Reduction 08 %

� Water Consumption Reduction 05 %

� Inventory Control Management Increase 05 %

� Environment Care Funds Increase 10 %

� Conversion of Disposable Hazardous Wastes To

Recycling Wastes About 02 %

� Increase Revenue Sources of Wastes 03 %

Wiring Devices Division

Energy Standards

� 10% Decrease in Energy

Utilization Through

Renewable Resources

� 05 % Decrease in Energy

Consumption in Machines

� Procurement of Energy

Efficient Machines

Sustainable AchievementsMore Sustainable

Competitors

Less Sustainable

Competitors

Comparative

Analysis Global NationalCompetitor - 1 Competitor - 1

Environmental Care

Funding

2836.57

MINR

18

MINR20 MINR <10 MINR

Factory Waste

Recycling Rates

Current

98.9 %

100%

Vision

30 % 35 % <4%

Renewable Energy

Resources

32000

MW2.0 MW 5.60 MW <1.0 MW

Comparative

Analysis Global NationalCompetitor - 2 Competitor - 2

Green House Gases

Emissions

10,000

Tons10 % 50 % < 5 %

Waste Water

Discharge &

Recycling

18.02

million

M3

60 % 98 % < 20 %

Waste Landfill

Disposal

3.4 Thousand

Tons

<5 % <2 % < 5 %

Area For Improvement

Area Already Improved

18/21

S. No. Project Title Approach Resource Required Timeline

1Reduce Wastage of Urea Formaldehyde Raw Material from 23.23% to 19.23%

Waste ReductionInfrastructure and Technology

2021-2023

2 Reuse 30% Scrap oil in Forming Machine Reuse and RecycleFeasibility study by Expert

2021-2022

3Reduction of Hazardous waste generation 2% by 3R technique

Waste ReductionInfrastructure and Technology

2021-2022

4Reduce Water Consumption 5% by adopting advance water saving techniques recommended in CII Water audit

Natural Resource SavingInfrastructure and Technology

2021-2022

5Reuse old Metal scrap for Development of New Molds

Reuse and RecycleInfrastructure and Technology & Feasibility Study done

2021-2023

6Energy consumption and CO2 emission reduction (8%) by Utilization of Renewable Energy

Energy ConservationInfrastructure and Technology

2021-2022

7Reduce Energy Consumption & CO2 emission (1%) by Adopting Godrej IFC Controller for reduce Loading Time of air compressor

New Process & Technology Equipment's

Technical & Commercial Working Completed

2021-2022

Priority Plans for +1 year and +2 year

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19/21

1- Deep understanding of waste management system of plant & conversion it into resources.

2- Strengthening of Input waste segregation system.

3- Better utilization of waste collection system and resources.

4- Elimination of Non-value added activities.

5- Process flow of waste in micro level.

6- The capital cost reduction because the project was developed In House.

7- Learned systematic approach towards improvements for environment saving.

8- Awareness of Plastic Waste Management Rule.

9- Enhance cost consciousness among team.

10- Culture of Environment Improvement through Sustainable Activities.

Major Learning From Projects

20/21Environment Performance Evaluation

Environment Performance FY 2018 FY 2019 FY 2020

Waste Generation

Used oil (KL) 27.3 29.8 20.1

Other Hazardous waste (Ton) 21.45 17.12 18.55

Urea Formaldehyde scrap (Ton) 965.20 716.56 710.44

Corrugated box (Ton) 26.59 24.51 21.54

Metal scrap (Ton) 252.73 210.00 235.48

Wooden scrap (Ton) 62.15 54.68 60.44

Plastic scrap (Ton) 319.90 210.74 76.92

Water Consumption (KL) 64.27 54.30 58.12

Air Emission

PM (gm/kw-hr) 0.134 0.119 0.091

SO2 (gm/kw-hr) 0.072 0.067 0.034

NOx (gm/kw-hr) 0.426 0.396 0.269

Sr. No. Parameter UOMEPA Permisible

LimitLocal

Regional

Capital

National

Capital

1 Particulate Matter (PM10) µg/M3 100.0 73.3 120.3 198.7

2 Particulate Matter (PM2.5) µg/M3 60.0 35.5 78.6 105.0

3 Sulphur Dioxide (as SO2) µg/M3 80.0 21.8 21.4 -

4 Nitrogen Dioxide (as NOX) µg/M3 80.0 24.0 24.6 70.5

Operational Performance Indicator (OPI)

Environment Condition Indicator

Management Performance Indicator (MPI)

*Annual Average

8929000

11628000

15688000

0

2000000

4000000

6000000

8000000

10000000

12000000

14000000

16000000

18000000

FY 2018 FY 2019 FY 2020

Bu

dg

et

(IN

R)

Environment Budget • Replacement of Dehumidifier to

Centralize dehumidifier system

(INR 6700000)

• Replacement of Single use plastic

by non-woven bag and

Corrufabricated box (INR 5690000)

• Installation of APFCR Panel in

Power factor improvement for

CO2 reduction (INR 1700000)

Major Environment Projects

2887.99

700.91

24.27

920.93

209.77

3.40

3128.00

726.50

23.23

709.211

161.542.27

0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

3500.00

Raw Material

(Ton)

Waste

Generation

(Ton)

Waste

Generation

(%)

Energy used

Anually (GJ)

CO2 emission

(Ton)

Water

Consumption

(KL)

FY 19-20 FY 20-21

19

20

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21/21

Panasonic Life Solutions India Pvt. Ltd.

Thanks

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